Intrinsically safe data acquisition system and apparatus

ABSTRACT

An intrinsically safe data acquisition system is disclosed for use in hazardous locations. The system includes a driller&#39;s console that itself is intrinsically safe and includes a large LCD monitor, keypad and local CPU. The system further includes satellite data acquisition and processing boxes that are also intrinsically safe and that are located within the hazardous area. Each satellite box includes its own CPU and acquires and locally processes signals received from a number of field sensors. The satellite box converts the signals into digital form, and transmits the data via a fiber optic communication channel to a master CPU box located in an unclassified area. A high current intrinsically safe barrier distributes power from the master CPU box to the satellite box for powering all the sensors supported by that satellite box. Another such barrier distributes all the power required by the driller&#39;s console.

FIELD OF THE INVENTION

The present invention relates generally to communication and controlsystems for use in monitoring and controlling various systems andequipment in industrial environments. More particularly, the inventionrelates to systems and apparatus for providing communications between,and a distribution of a control voltage to, equipment and deviceslocated in areas that are classified as hazardous due to the presence ofexplosive vapors or dust. Still more particularly, the invention relatesto intrinsically safe monitors and other apparatus housing a CPU andassociated electronics that are located in class 1, division 1locations.

BACKGROUND OF THE INVENTION

At locations where oil or gas wells are being drilled, a number offlammable gases may be present, including mixtures of oxygen, methane,ethane, propane, hydrogen sulfide and others. Similar potentiallydangerous environmental conditions exist in locations in which petroleumproducts are being recovered, refined or processed. Likewise, inindustrial areas where large quantities of dust are present, such as ingrain handling facilities or pulp and paper mills, hazardousenvironmental conditions may exist. Standardized classifications for thevarious types of hazardous locations have been adopted and assigned byregulatory agencies according to the nature and type of hazard that isgenerally present or that may occasionally be present.

Because electrical components, by their nature, may generate heat andsparks sufficient to ignite a flammable gas or other flammable mixtureunder even normal operating conditions, such components must becarefully selected and installed when used in an area that is classifiedas hazardous. More specifically, the components must exceed certainminimum standards as to such characteristics as power consumption,operating temperature, current and voltage requirements, and energystorage capabilities. These standards are also established by regulatoryauthorities and vary depending upon the particular hazardousenvironment.

Certain electrical devices are intrinsically safe. An intrinsically safedevice may be generally described as a device that during normaloperation, as well as operation during any fault condition, cannot causea spark or achieve a temperature sufficient to ignite the gas or othersubstance that is present and that causes the area to be classified. Ifa device is not intrinsically safe, other means must be provided toensure that the device cannot serve as a source of ignition. Typicallywhere a device is not intrinsically safe, it may be made safe by housingit in an explosion proof enclosure, or by enclosing the device in someother type of enclosure and purging the enclosure with "clean" air. Anexplosion proof box or enclosure is one that will prevent any explosionthat might occur within the box from causing the atmosphere outside thebox to ignite. Purging an enclosure with a continuing source of cleanair prevents the air that is laden with the hazardous substance fromentering the box, such that a spark or elevated temperature of thecomponent within the box cannot ignite the hazardous atmosphere.

Although areas that are classified as hazardous are prevalent in manyindustries, the problems of powering and communicating with electricaldevices in hazardous areas are particularly acute in the drillingindustry. In drilling a well, a great deal of equipment is located inclose proximity to the well head, including mud pumps, compressors, mudpits and other subsystems associated with drilling, Many of these areasaround a drilling site are classified as hazardous, and thus specialprecautions are required with respect to the electrical communicationand power distribution systems. To efficiently and safely control thedrilling operation, the driller will require a system having sensorspositioned in a number of locations in the hazardous area. These sensorswill transmit needed data to a computer which can process that data andtransmit important information to the driller by means of a driller'sconsole or monitor. By viewing the information on the driller's monitor,the driller can then make whatever changes are appropriate to the systemto assure safe and continuing operation.

The driller's monitor is typically required to be very close to the wellhead and thus is located in a hazardous area. Historically, drillerconsoles have varied with respect to the amount of information displayedand type of indicators used. In the past, when a simple meter or gageprovided all the information that was required, the device couldsometimes be made intrinsically safe. However, due to the sophisticationof today's drilling practices, consoles or monitors usually must providea driller with a tremendous amount of information concerning thelocation and orientation of the drill bit, the mud flow rates, downholepressures, as well as the status of the other systems supporting thedrilling operation. Additionally, the console must permit the driller toissue commands or make inquiries through the use of a keyboard or keypad, and must display all the needed information by means of a CRT orother sophisticated monitor. These modern driller's consoles or monitorshave a substantial power requirement that has prevented them from beingmade intrinsically safe, and that requires that they be housed in anexplosion proof or a purged enclosure. Due to its size and extremeweight, an explosion proof enclosure is typically not practical forlarge consoles. Accordingly, is has been the usual practice to housetoday's monitor in a purged enclosure.

There are several distinct and significant disadvantages associated withthis conventional practice. First, purged air is typically supplied in aform that includes an oil mist that has been added to the system toassure proper operation of air compressors. The oil mist is both anuisance and, over time, can have a detrimental effect on the electroniccomponents. Additionally, and significantly, purge air has often provedto be unreliable due to various mechanical failures. When the purge airis lost, the system must automatically be shut down to avoid thepossibility of ignition of flammable gases. The driller has a tremendousfinancial investment in the operation at the drilling site such thateven a short shutdown is extremely costly.

Furthermore, purge air systems require the installation of piping fromthe air source to the monitor, and to other devices receiving the purgedair. This investment is one that the driller would prefer not to makebecause it typically will be removing its equipment and personnel fromthe drilling site after a relatively short length of time. Thus thesemi-permanent nature of installing pipe, the extra time involved ininstalling the piping, and the additional monitoring and backupequipment necessary to ensure the integrity of the purged air system areall costly additional investments the driller would prefer to avoid ifan alternative was available.

Additional drawbacks or compromises exist or are required in theconventional data acquisition systems currently used by drillers. Asmentioned above, various sensors are positioned about the drilling sitein hazardous locations. Electrical conductors, which provide power and acommunication means to and from the sensors, are routed from each sensorto a junction box which is also located in the hazardous area. Thesejunction boxes receive power from and communication signals to and fromanother box that is located outside the hazardous area and whichincludes an intrinsically safe barrier (ISB) for each of the sensorsinterconnected through that box. Conventional ISBs limit the current andvoltage that is conducted to a sensor to ensure that the power reachingthe sensor is not of a magnitude that might permit the device to ignitethe atmosphere in the hazardous area. Using this conventional system,one ISB is required for each sensor. Accordingly, it is typical practiceto interconnect each junction box with the box containing the ISBs bymeans of a relatively bulky and expensive multiconductor cable.Likewise, another multiconductor cable typically interconnects the boxcontaining the IBSs to a computer or other central controller which islocated outside the hazardous area.

As is obvious, the conventional arrangement thus described is againcostly and time consuming to install. First, a substantial number ofISBs will be required given that a typical drilling system may monitortwenty or more different parameters. Further, the multiconductor cablesinterconnecting the ISB box to the central controller and to the variousjunction boxes are relatively heavy and bulky. It can be time consumingand difficult to route and install the required conduit and then pullthe cables in the installed conduits.

Further, the driller's equipment is typically used sequentially in anumber of separate jobs such that it is installed, dismantled andreinstalled on a fairly frequent basis. Accordingly, running piping forpurge air, routing and locating bulky and heavy multiconductor cablesand conduits, and handling and installing heavy explosion proofenclosures is typically not practical and, at a minimum, undesirable.

Additional drawbacks to conventional data acquisition systems alsoexist. Due to the nature of a drilling site, the field sensors andcables are typically installed in an electrically noisy environment.Even with shielding, the multiconductor cables are vulnerable to straynoises generated in the area and, until the desired signals reach thecentral controller outside the hazardous area, there is generally nomeans provided for filtering or conditioning the signals. Finally, giventhat conventional systems merely retrieve field-generated signals andtransmits them all to the central controller for processing, the centralcontroller may be heavily loaded with tasks associated with dataprocessing and calculation.

Accordingly, despite the fact that there currently exists workable dataacquisition systems for use in and about hazardous environments, thereremains a need for safe, less cumbersome and low cost means foracquiring and manipulating data from the various sensors. Morespecifically, an intrinsically safe driller's monitor, one not requiringan explosion proof enclosure or purge air and the significant drawbacksassociated with such a system, would be particularly welcomed by theindustry. Furthermore, a system which could provide power to the varioussensors and acquire data therefrom without requiring the conventionalnumber of ISBs would be a significant advance in this technology. Also,a system which would reduce the communication system's susceptibility toelectrical noise and that would be less burdensome and costly toinstall, dismantle and transport would be especially welcomed by thedrilling industry.

SUMMARY OF THE INVENTION

Accordingly, there is provided herein an intrinsically safe dateacquisition system for use in areas classified as hazardous due to thepresence of ignitable vapors, dust or the like. The invention generallyincludes a master CPU box that is located outside the hazardous area fordistributing power to the other system components. An intrinsically safesatellite box is located within the hazardous area for redistributingpower to, and collecting signals from various sensors that are locatedin the hazardous area. The invention further includes an intrinsicallysafe console, including monitor, that is located within the hazardousarea for communicating with the master CPU box. A barrier box isincluded in the system and located outside the hazardous area forreceiving power from the master CPU box and safely redistributing thepower to the intrinsically safe satellite box and console.

The intrinsically safe console preferably includes a monitor having alarge format LCD screen and a data input device, such as a keypad orkeyboard. The console includes an onboard micro-controller andcommunication circuitry allowing the operator using the console tocommunicate with the master CPU box, preferably via fiber-optic cable.Because of the low power requirements of the console, an explosion proofor purged housing or enclosure is not required. The console isintrinsically safe for Class 1, Division 1, Groups C and D, locations.

The satellite box of the present invention is an intrinsically safe datacollection and processing center. The satellite box transmits power tothe total of up to 10 analog and digital sensors. The box receives thesignals from the sensors and converts them to digital form fortransmission to the master CPU box via a single communication channel,preferably a fiber-optic conductor. The satellite box preferablyincludes an on-board CPU for converting the analog signals to digital,processing those signals, deriving calculated data, and transmittingthat data outside the hazardous area. The box further includes signalconditioning means for the received analog and digital signals, as wellas independent voltage regulating means for each sensor. The box isintrinsically safe for Class 1, Division 1, Groups C and D locations.

The present invention eliminates the need for expensive and heavyexplosion proof enclosures for consoles and boxes that are to be locatedin hazardous areas. The invention also eliminates the need forinstalling permanent or semi-permanent piping for supplying purged airto such enclosures. Further, the invention permits an operator in thehazardous area to visually monitor a large amount of data and toeffectively communicate with a master CPU box located outside ahazardous area. Furthermore, the local processing of data within thesatellite box and transmitting that data via a single communicationchannel eliminates the need for bulky and expensive multi-conductorcables otherwise required for sending individual signals to the masterCPU box outside the hazardous area. Additionally, the inventioneliminates the previously existing problem of electrical noise beinginduced in the long, multiconductor cable runs, eliminates the number ofintrinsically safe barriers traditionally required to safely operate adata acquisition system within a hazardous area, and further relievesthe master CPU box from certain data processing duty.

Thus, the present invention comprises a combination of features andadvantages which enable it to substantially advance the area oftechnology concerning data acquisition and communications withinhazardous areas. These and various other characteristics and advantagesof the present invention will be readily apparent to those skilled inthe art upon reading the following detailed description of the preferredembodiments of the invention and by referring to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram showing, in schematic form, the elementscomprising the data acquisition system of the present invention.

FIGS. 2 and 3 are front and side views, respectively, of the satellitebox shown in FIG. 1.

FIG. 4 is a plan view of the satellite PCB housed in the satellite boxshown in FIGS. 2 and 3.

FIG. 5 is an electrical diagram, in schematic form, showing theinterconnection of the various components of the satellite PCB shown inFIG. 4.

FIG. 6 is a plan view of the communication module PCB that is connectedto the satellite PCB shown in FIG. 4.

FIG. 7 is an electrical schematic showing the interconnections of thecomponents mounted on the PCB shown in FIG. 6.

FIG. 8 is a front view of the barrier box shown in FIG. 1 with a portionof the cover cut away to show the intrinsically safe barriers and otherinternal components.

FIG. 9 is a section view of the barrier box shown in FIG. 8 taken alongline 9--9.

FIG. 10 is a schematic diagram showing the components of the highcurrent intrinsically safe barrier employed in the barrier box shown inFIGS. 8 and 9.

FIGS. 11 and 12 are front and side views, respectively, of theintrinsically safe driller's monitor shown in FIG. 1.

FIG. 13 is a section view of the driller's monitor taken along line13--13 of FIG. 11.

FIG. 14 is an elevation view of the inside of the cover of the driller'smonitor shown in FIGS. 11-13 showing the various PCBs and theinterconnecting ribbon connectors.

FIG. 15 is a plan view of the monitor interface PCB that is housed inthe driller's monitor shown in FIGS. 11-13.

FIG. 16 is an electrical diagram in schematic form, showing theinterconnections between the various components on the monitor interfacePCB shown in FIG. 15.

FIG. 17 is a plan elevation view of the CPU board housed in thedriller's monitor shown in FIG. 13 and 14.

FIG. 18 is a plan view of the LCD driver board housed in the driller'smonitor shown in FIGS. 13 and 14.

FIG. 19 is an electrical diagram, in schematic form, showing theinterconnection of the components of the interface PCB that is housed inthe CPU box shown in FIG. 1.

FIG. 20 is an electrical diagram, in schematic form, representative ofeight separate circuits contained in the 8-channel breakout PCB housedin the CPU box shown in FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENT

It is frequently necessary to monitor and control various electricalsystems and subsystems that are located partially or totally withinhazardous areas, such as those where explosive vapors may be present.The present invention discloses a data acquisition, communication andcontrol system that may safely be employed in such hazardous areas, thesystem as a whole, and specific subsystems themselves, beingintrinsically safe. The invention has particular utility when used on adrilling site to interconnect the driller's monitor, a central or mastercontroller and various sensors that are located throughout the drillingsite. Accordingly, the preferred embodiment of the present inventionwill be described with reference to employing the invention on adrilling site; however, it is to be understood that the invention is notlimited to such applications, but instead is broadly applicable to anyof a myriad of situations where computers, monitors and sensors are tobe located in areas classified as hazardous,

Referring now to FIG. 1, the intrinsically safe data acquisition system(DAS) 10 of the invention is generally shown, DAS 10 generally includesa central or master CPU box 12, a barrier box 14, an intrinsically safedriller's monitor 16, and one or more intrinsically safe satellite boxes18-20. Additionally, DAS 10 includes an intrinsically safe audiblealarm, such as horn 22 and any number of intrinsically safe sensors suchas sensors 31-38.

The drilling site includes an unclassified or nonhazardous area 1 and ahazardous area 2, the dividing line between such areas being generallydepicted in FIG. 1 by dashed line 3. Areas are classified according tothe presence or likely presence of explosive vapors. The standards forsuch areas are established by the American Petroleum Institute (API) andare published in the API "Recommended Practices for Classification ofLocations for Electrical Installations at Petroleum Facilities," APIRecommended Practice 500 (RP500), First Edition, Jun. 1, 1991,specifically incorporated herein by this reference. In a typicaldrilling site, hazardous area 2 typically may be classified as a Class1, Division 1, Groups C and D hazardous location due to the likelypresence of hydrogen sulfide. Other Group D gases may also be present.Other gases in Group D include benzene, butane, ethane, gasoline,methane, propane and others. A complete listing of Group C and D gasesis included in Article 500 of the National Electric Code Handbook, SixthEdition, based on the 1993 Edition of the National Electric Code,published by the National Fire Protection Association, the entiredisclosure of Article 500 being hereby specifically incorporated by thisreference. As shown in FIG. 1, sensors 31-38, satellite boxes 18-20,horn 22 and driller's monitor 16 are all physically located within thehazardous area 2. Accordingly, driller's monitor 16, satellite boxes18-20, sensors 31-38 and horn 22 are all intrinsically safe. Bycontrast, master CPU box 12 and barrier box 14 are located inunclassified area 1 and therefore are not required to be intrinsicallysafe. Optional displays or monitors 24, 25 and optional circularrecorders such as recorder 26 shown in FIG. 1 are also located inunclassified area 1 and thus likewise need not be intrinsically safe.

The driller's monitor 16, satellite boxes 18-20 and the 15 volt, 5 ohmhigh current ISBs 62 (which is described in detail below and whichassists in distributing power from the master CPU box 12) have each beencertified as intrinsically safe and non-incendive for use in hazardouslocations in accordance with Canadian Standards Association ("CSA")Standard No. C22.2 No. 157-M1987. The ISBs 62, driller's monitor 16 andsatellite boxes 18-20 have received the certification by the CSA forclass 1, division 1, group C and D locations. The CSA certifications areacceptable by all U.S. and Canadian regulatory bodies, including forexample, the U.S. NFPA and the U.S. Coast Guard. The standards forelectrical equipment being certified intrinsically safe andnon-incendive are set out in the standards as published in May 1987 bythe CSA, 178 Rexdale Boulevard, Rexdale, (Toronto) Canada M9W1R3. Thestandard is entitled "C22.2 No. 157-M1987 Intrinsically Safe andNon-lncendive Equipment for Use in Hazardous Locations, Consumer andCommercial Products forming part of Canadian Electrical Code, Part IISafety Standards for Electrical Equipment, ISSN0317-5669," the entiredisclosure of which is incorporated herein by this reference. The CSAhas also published additional standards relating to non-incendiveequipment for use in class 1, division 2 hazardous locations, Suchstandards include various charts and tables showing ignitiontemperatures and currents and voltages that may ignite explosive vaporsof various types and which relate to Standards C22.2 No, 157-M1987regarding Intrinsically Safe and Non-Incendive Equipment. Accordingly,also incorporated herein by this reference is the CSA's standard C22.2No. 213-AM1987 entitled "Non-lncendive Electrical Equipment for Use inClass 1, Division 2 Hazardous Locations--Industrial Products FormingPart of Canadian Electrical Code, Part II Safety Standards andElectrical Equipment" published in March 1987 by the Canadian StandardsAssociation.

SYSTEM OVERVIEW

Before describing the various apparatus, subsystems and features of thepresent invention in greater detail, a general overview of the system isprovided. In general, to monitor and control modern, sophisticateddrilling equipment, a variety of sensors 31-38 are employed to detectand communicate various parameters to master CPU box 12. Such sensorsare typically located in or near the various pumps, compressors,drilling fluid (mud) pits and tanks. Such sensors are interconnectedwith intrinsically safe satellite box 18. Although not shown, a numberof other sensors would likewise each be interconnected with satellitebox 19 or 20.

The signals generated by the various field sensors must be communicatedto master CPU box 12. The signals from each group of sensors arecollected by their respective satellite box 18-20. Each satellite box18-20, which may collect both analog and digital signals from itsrespective sensors, converts all the received analog signals to digital,and then transmits those digital signals and any calculated data throughbarrier box 14 to master CPU box 12 via fiber optic cables. Eachsatellite box 18-20 includes a CPU for data processing and thus relievesmaster CPU box 12 of some of the data processing burden.

The barrier box 14 includes intrinsically safe barriers (ISBs),sometimes referred to as "current barriers" or "zener barriers." Barrierbox 14 includes a separate intrinsically safe barrier for driller's box16, horn 22 and each satellite box 18-20. The intrinsically safebarriers ensure that the power distributed to each of these peripheralsis at a current level and voltage level that will not ignite thehazardous vapors.

The power to operate all the components of DAS 10 is supplied frommaster CPU box 12. That power is then distributed to driller's monitor16, horn 22 and satellite boxes 18-20 through barrier box 14. Master CPUbox 12 also distributes power to the optional displays 24-26; however,such power distribution need not pass through barrier box 14 since thesemonitors are located in unclassified area 1.

Driller's monitor 16 includes an LCD display, keypad and local CPU foruse in communicating with master CPU box 12. Communications betweenintrinsically safe monitor 16 and master CPU box 12 likewise areconducted through barrier box 14 via fiber optic cables as describedmore fully below.

SENSORS

Typical sensors for use in the DAS 10 of the present invention includeup to eight mud pit probes, two trip tank probes, a flow paddle andthree pump stroke rate detectors, all of which are intrinsically safe.If all the above-identified devices are employed in the DAS 10, thesystem will require two satellite boxes 18 and 19 as shown in FIG. 1.Any analog sensor may be connected to any analog channel in anysatellite box. Likewise, any digital sensor can be connected to anydigital channel of any satellite box.

In other applications, a variety of additional sensors may be desirable.Thus, depending upon the total number of sensors, a third satellite box20 may be required. Particularly desirable additional sensors includesensors indicating tool depth, rotary RPM, hookload, pump pressure,casing pressure, hydraulic rotary torque and electric rotary torque.With these seven additional sensors, a myriad of other calculatedparameters can be locally derived within satellite boxes 18-20 and thentransmitted to master CPU box 12.

SATELLITE BOX

Referring again to FIG. 1, the satellite box 18-20 is an intrinsicallysafe, microprocessor controlled, data acquisition module having atemperature code T3C for Class 1, Division 1, Groups C and D, hazardouslocations as set out in Table 2 in CSA standard C22.2 No. 157-M1987.Because of its intrinsically safe certification, including the requisitespark ignition and thermal ignition testing set out in C22.2 No.157-M1987, neither the satellite box nor any of its components arecapable of igniting a Group C or D gas in normal use, or under anyconditions of fault likely to occur in practice. At an ambienttemperature of 40° C., the maximum surface temperature of components insatellite box 18-20 under fault conditions is 160° C.

Each satellite box 18-20 is capable of supporting eight analog channels(either voltage or current transmitter) and two digital channels.Effectively then, each satellite box can transmit power andcommunication signals to and from up to ten different sensors 31-38. Thesatellite box is sensor unspecific in that it has the ability to utilizeany presently available and commonly employed sensors. All analogchannels include a two point calibration means. All digital channels arehigh end calibratable.

As previously mentioned, the satellite box 18-20 is interconnected andcommunicates with the master CPU box 12 through the barrier box 14. Thiscommunication is accomplished by means of composite cables 41-43comprising three electrical conductors, two fiber optic conductors, adrain and a shield.

Each satellite box is rated intrinsically safe by the Canadian StandardsAssociation and contains a stand-alone CPU. The satellite box receivespower via ISB's housed in the barrier box 14. The power is conditionedonboard to maintain the intrinsically safe characteristics, as well asto remove any electrical contamination (noise) that may have beenintroduced in transmission from the master CPU box to the satellite box.

The parameters sensed by sensors 31-38 are communicated electricallyfrom the sensors to the satellite box CPU. All conversion of signalsfrom analog to digital is done in the satellite box. Rates andaccumulation of digital inputs are processed within the satellite box.The satellite box's onboard CPU microcontroller converts the sensedvalues into a digital data stream and, upon being polled by the masterCPU box 12, transmits the acquired and converted data serially from thehazardous area to the master CPU box via the barrier box 14 and fiberoptic conductors in cables 41-43.

The details regarding satellite boxes 18-20 are best understood withreference to FIGS. 2-5 and associated Table 5. Because boxes 18-20 areidentical, a description of box 18 will describe all such boxes.

Referring to FIGS. 2 and 3, box 18 generally includes a hinged enclosure50. The enclosure 50, and the enclosures for master CPU box 12, barrierbox 14, intrinsically safe monitor 16, are all preferably made of blownfiberglass and are EMI shielded by an internal nickel-based coating.Such enclosures may be supplied by Carlon, A Lamson & Sessions Company,and are all NEMA 4x rated.

The satellite box enclosure 50 houses satellite PCB 52 (sometimesreferred to as a data acquisition board) which is mounted by fourstandoffs 53 from the enclosure's mounting plate 54 which is located inthe rear portion of the box. The lower end of the box includes ten cableconnectors 56 which provide means for receiving and connecting theelectrical cables that are routed between satellite box 18 and fieldsensors 31-38.

Satellite PCB 52 is best shown in FIG. 4 which shows the physical layoutof the components supported by the board which are shown and identifiedmore particularly in FIG. 5 and the associated Table 5. These componentsare particularly situated on board 52 to ensure that satellite box 18 isintrinsically safe. More specifically, the board 52 includes no largecapacity capacitors or inductors. Further, the various components areselected such that none are capable of igniting vapors that may bepresent in the hazardous area 2, either by virtue of either temperatureor sparking at either normal or fault conditions.

Referring now to FIG. 5 and its associated Table 5, satellite PCB 52will be described in more detail.

                                      TABLE 5                                     __________________________________________________________________________                                                              MATL                DESIGNATOR     QTY                                                                              NO.                                                                              PART NO.                                                                            DESCRIPTION                    REQD                __________________________________________________________________________                   1  50 LSS00017                                                                            BAG STATIC SHIELDING 10 × 12 ANT-STATIC                                 FOAM                           1                                  5  49 YML00020                                                                            TERMNL UNINS TEST PT. .090     5                                  1  48 YKH99020                                                                            JUMPER BERG STICK 65474-001    1                                  1  47 YMP00032                                                                            SOCKET IC 8 PIN                1                                  2  46 YMP00010                                                                            SOCKET IC 14 PIN               2                                  1  45 YMP00011                                                                            SOCKET IC 16 PIN               1                                  2  44 YMP00076                                                                            SOCKET IC 20 PIN               2                                  1  43 YMP00080                                                                            SOCKET IC 28 PIN               1                                  1  42 68-65-075                                                                           SOCKET IC 68 PIN SOUARE PLCC   1                                  8  41 65-90-506                                                                           TERMNL BLOCK PCB CONN 5 PIN    8                                  3  40 65-90-497                                                                           TERMNL BLOCK PCB CONN PLUGGABLE 4                                                                            3IN                                1  39 YKH99030                                                                            BERG STICK 3 POSITION          1                   P5-P12         8  38 65-05-025                                                                           CONNECTOR 5 PIN HEADER SHROUDED PCB                                                                          8NT                 P2,P3,P4       3  37 65-04-015                                                                           CONNECTOR 4 PIN HEADER SHROUDED PCB                                                                          3NT                 P1             1  36 65-25-010                                                                           TERMNL BLOCK CONNECTOR 25 PIN D PCB MNT                                                                      1ALE                VR6-VR13       8  35 67-23-367                                                                           IC LM2950ACZ VOLTAGE REGULATOR 5 V LOW                                                                       8OWER               VR5            1  34 67-23-336                                                                           IC LM78M15CT VOLTAGE REGULATOR 15                                                                            1                   VR3,VR4        2  33 67-95-025                                                                           IC TK1168 VOLTACE REGULATOR 8 V LOW                                                                          2ROPOUT             VR2            1  32 67-23-366                                                                           IC LM2940 VOLTAGE REGULATOR 5 V LOW                                                                          1ROPOUT             VR1            1  31 67-23-355                                                                           IC LM117L VOLTACE REG ADJ      1                   U8             1  30 YJE0000B                                                                            IC MC1449OP HEX BOUNCE ELEMINATOR                                                                            1490                U7             1  29 67-95-513                                                                           IC RS232 LINE DRIVER/RECEIVER                                                                                1P233               U5             1  28 67-95-795                                                                           IC 80C552 MICRO CONTROLLER 10 BIT                                                                            1/D                 U4,U5          2  27 YJA00040                                                                            IC LM324N QUAD OP-AMP LOW PWR  2                   U3             1  26 96-65-030                                                                           SOFTWARE J-BOX SATELLITE       1                   U2             1  25 67-95-780                                                                           IC TRANSPARENT LATCH 74HCT373  1                   U1             1  24 67-05-700                                                                           IC REF-02 VOLTAGE REFERENCE    1                   S3,S4          2  23 YSL11101                                                                            SWTCH DIP ROCKER 8 PST 200 V                                                                                 2DRR-4-185          S2             1  22 75-79-020                                                                           SWITCH DPDT PCB MNT 300 MA 125                                                                               1                   S1             1  21 75-78-060                                                                           SWITCH SPST ROTARY PCB MNT 500 MA 125                                                                        1                   X1             1  20 YBA11050                                                                            CRYSTL 11.0592 MHZ E1105       1                   D1             1  19 YDE04020                                                                            DIODE IN5817 SCHOTTKY 1 AMP 20                                                                               1                   LD1            1  18 68-15-010                                                                           LED GREEN RECT                 1                   O1             1  17 74-78-833                                                                           XSISTR 2N3904 MOTOROLA         1                   C14            1  16 W05001157                                                                           CAPCTR 2.2 MFD 50 V KEMET      1                   C13            1  15 YCG31004                                                                            CAPCTR .001 MFD FILM ± 10%                                                                                18F2246             C8,C10         2  14 YCC33305                                                                            CAPCTR 33 PF 50 V RECT CERAMIC 2                   C2,C3,C5,C6,C11,C12,C15-C23                                                                  15 13 61-50-007                                                                           CAPCTR .10 MFD 100 V           15                  C1,C4,C7,C9,C24-C31                                                                          12 12 YCA30100                                                                            CAPCTR 1 MFD 35 V TANT 47F404  12                  R25,R26        2  11 YRA14122                                                                            RESIST  1/4W 1200 OHM 5%       2                   R17-R24        8  10 72-05-139                                                                           RESIST  1/4W 1M OHM 1% RN55D                                                                                 8/B                 R15,R16        2  9  72-06-576                                                                           RESIST  1/4W 1.8K OHM 5% CARBON                                                                              2                   R7-R14         8  8  72-03-059                                                                           RESIST  I/8W 249 OHM 1% METAL                                                                                8ILM                R5             1  7  72-04-073                                                                           RESIST  1/4W 1000 OHM .1% METAL                                                                              1ILM                R6             1  6  72-04-058                                                                           RESIST  1/4W 240 OHM .1% METAL                                                                               1ILM                R4             1  5  YRG82013                                                                            RESIST  1/8W 1000 OHM 1%       1                   R3             1  4  YRG82392                                                                            RESIST  1/8W 3920 OHM 1%       1                   R2             1  3  YRA14103                                                                            RESIST  1/4W 10000 OHM 5%      1                   R1             1  2  YRA14471                                                                            RESIST  1/4W 470 OHM 5%        1                                  1  1  96-52-105                                                                           PCB BLANK                      1                   __________________________________________________________________________

Satellite box 18 includes a 10-bit microcontroller U5 having an internalanalog to digital converter. The preferred microcontroller is anintegrated circuit model number IC80C552 manufactured by PhillipsSemiconductors. Connectors P5-P15 interconnect sensors 31-38 andmicrocontroller U5 and thus provide pins for providing power to and thereturn signal from sensors 31-38. The voltage supplied to each sensor31-38 is regulated by a dedicated 5 volt, low power, voltage regulatorsV6-V13. Additionally, with respect to the 15 volt signal which somesensors may require, a single 15 volt regulator VR5 is provided.Separate voltage regulation on the 5 volt supply was provided to ensurethat in the event one circuit to a sensor was damaged or shorted, thesatellite box 18 could continue to supply power to and monitor theremaining sensors which would be unaffected. VR6-VR13 are preferably ICsmanufactured by National Semiconductor Corporation, having Model No.LM2950ACZ which essentially have internal short circuit protection whichwill automatically return power to the field sensor once the fault ordisturbance has been removed. Without separate such voltage regulatorsVR6-VR13, the 5 volt power to and return signal from each sensor 31-38would be lost even in the event that only one field cable to one sensorhad been damaged. It is anticipated that primarily 5 volt sensors willbe employed in the field. Accordingly, the redundant voltage regulationof the 15 volt signals has not been provided, although optionally may beand, where the cost was justifiable, preferably would be provided.

For sensors employing 15 volt supply, typically those that generate 4 to20 milliamp signals, dropping resistors R7-R14 are provided to give avoltage signal in the 1-5 volt range that microcontroller U5 can accept.

Satellite PCB 52 includes signal conditioning circuitry to filter noisefrom all signals returning from field sensors 31-38. The conditioningcircuitry can bias the returning signals to provide a full 0 to 5 voltsignal to microprocessor U5. The signal conditioning means includes quadop amp, low power integrated circuits U4 and U6 such as Part No. LM324Nas supplied by National Semiconductor Corporation. Voltage regulator VR1is provided in the signal conditioning circuitry in order to generate a6.5 volt signal to aid in biasing or expanding the range of signals sothat the microprocessor will receive the full 0 to 5 range. This signalconditioning circuitry further includes resistors R17-R24 and capacitorC16-C23 as shown in FIG. 5 adjacent to op amps U4 and U6.

The code or operating instructions for microcontroller U5 is stored in aread only memory, preferably an EPROM such as designated as U3 in FIG.5. Preferably microcontroller U5 runs strictly from instructionsprovided by EPROM U3. Latch U2 is provided between microcontroller U5and EPROM U3 as bus control and as an address control for microprocessorU5.

The signals received from digital field sensors are received at P3 andP4. Voltage regulators VR3 and VR4 ensure that 8 volts are provided tothe sensors. U1 is a voltage regulator which supplies 5 volts DC to themicrocontroller U5 and to a hex bounce eliminator (digital debouncer) U8such as Model No. MC14490P as manufactured by Motorola, Inc. Thedebouncer U8 rejects digital noise returning with the signal provided bywhatever digital sensors are located in the field. Again, VR3 and VR4separately supply 8 volts to the digital sensors to prevent a fault ordisturbance on the cable servicing one sensor from causing a loss ofpower to and signal from the other digital sensor.

For system integrity, it is preferred that various components orcircuits on the satellite PCB 52 be provided with separate voltageregulators which are positioned as close as possible to the circuitbeing supplied so as to decrease the possibility that radiated orinduced noise from rig equipment will disrupt or hamper communicationswithin DAS 10. Although separate voltage regulators are preferred, asingle 5V, 8V and 15 volt regulator could be used instead to power allcircuitry on PCB 52.

The digital field sensors may include proximity switches or a simplemechanical make-or-break switch. Such sensors may be used to pick up mudpump piston strokes. Such information can be recorded in themicrocontroller U5 and accumulated for transmission to master CPU box12. Additionally, using the acquired and accumulated data variouscalculations can be made within microcontroller US, such as pump rpm,which again can be transmitted to CPU box 12.

Rotary switch S1 is an 8-position switch that, in conjunction withtransistor Q1 and LD 1 provide a troubleshooting feature enabling anoperator to select various positions and obtain a visual indication ofdata transmission into or away from the PCB 52.

Power into satellite PCB 52 is supplied at connector P2 from compositecable 41 which carries both the 24 volt and 12 volt supply from thebarrier box 14. The nominal 12 volt supply is conducted to diode D1which prevents reverse flow. Depending on the length of the conductorsand the other resistances in the system, board 52 is supplied with a DCvoltage of about 9 to 11 volts after dropping through D1. FIG. 5indicates an 11.7 volt DC signal which is the highest or best casevoltage.

U7 is an RS232 line driver/receiver to enable communications betweenmicrocontroller U5 and master CPU box 12 (FIG. 1) Preferably U7 is an ICas manufactured by Sipex Corporation, Part No. SP233EP. P1 is a 25 pinmale connector on which is mounted a communication module 58 describedbelow, the communication module 58 converting the electrical signals tothe fiber optic signal for communication with a similar communicationsmodule in master CPU box 12. The communication module 58 is normally setto receive and convert RS232 signals. In the event that otherapplications require a different communication protocol, such as RS485or 422, switch S2 effects a change so that signals transmitted to pin 2and received at pin 3 of connector P1 will be reversed, such that thesignals will be instead transmitted to pin 3 and received at pin 2.

FIGS. 6 and 7, along with Table 7, depict and describe communicationmodule 58.

                                      TABLE 7                                     __________________________________________________________________________                                                              MATL                DESIGNATOR                                                                             QTY                                                                              QTY                                                                              NO.                                                                              PART NO.                                                                             DESCRIPTION                      REQD                __________________________________________________________________________             1  1  17 LSS00016                                                                             BAG STATIC SHIELDING 8 × 12 FOAM/MACKPAC       U5       1     16 70-80-065                                                                            RECIVER FIBER OPTIC PCB MNT HORIZ 49K BD                                      PLASTIC                                              U4       1     15 70-65-065                                                                            XMITER FIBER OPTIC PCB MNT HORIZ 40K BD PLASTIC                  1  14 65-90-506                                                                            TERMNL BLOCK PCB CONNECTOR PLUGGABLE 5 PIN           R2       1     13 YRA14472                                                                             RESIST 4700 OHM  1/4W 5%                                            12                                                             C1       1  1  11 YCA30100                                                                             CAPCTR 1 MFD 35 V TANT 47F404                        C2-C5    4  4  10 61-50-007                                                                            CAPCTR 100 V .1 MFD KEMET C330CTD4MICUICA            VR1      1  1  9  67-23-367                                                                            IC LM2950ACZ VOLTAGE REGULATOR 5 V LOW POWER         O1       1     8  74-78-833                                                                            X5i5TR 2N3904 MOTOROLA                               U1          1  7  70-65-020                                                                            XMITER CURRENT LOOP OPTICALLY COUPLED 20 MA          U2          1  6  70-60-020                                                                            RECIVR CURRENT LOOP OPTICALLY COUPLED 20 MA          U3       1  1  5  87-95-513                                                                            IC RS232 LINE DRIVER/RECEIVER                        P3          1  4  65-60-025                                                                            CONCTR 5 PIN HEADER SHROUDED PCB MNT                 P2       1  1  3  65-01-001                                                                            CONCTR 1 PIN PCB RA MICRO-D JAX                               1  1  2  65-25-015                                                                            CONCTR 25 PIN D FEM W/WIRE WRAP TAXS                          1  1  1  96-52-123                                                                            PCB BLANK D-CONN COM MDO                             __________________________________________________________________________

Communication module 58 includes a 25 pin female plug, designated onFIG. 7 as P1, which engages male plug P1 shown in FIG. 5. Communicationmodule 58 includes fiber optic cable connectors U4 and U5 fortransmitting and receiving, respectively, the desired data along fiberoptic conductors contained in composite cable 41. Transmitter andreceiver current loops U1 and U2, respectively, and RS232 linedriver/receiver U3, in conjunction with transistor Q1, allow fiber opticcommunication to be conducted between master CPU box 12 and satellitebox 18. VR1 is a low power, 5 volt, voltage regulator which may beidentified to those designated as VR6-VR13 previously described withrespect to FIG. 5.

BARRIER BOX

The barrier box 14 houses intrinsic safety barriers to distribute powerto the driller's monitor 16, the satellite boxes 18-20, the audiblealarm 22, and, ultimately, to the various sensors which are located inhazardous locations. Communications from barrier box 14 to theseperipherals is via fiber optic cable which provides both safety and anelectrical noise insensitive communication means.

Barrier box 14 is best shown in FIGS. 8 and 9. Barrier box 14 includesenclosure 60 which is again a blown fiberglass shielded, hinged NEMA 4xenclosure. In the preferred embodiment, enclosure 60 houses four highcurrent, 15 volt, 5 ohm intrinsically safe barriers 62, and four 25.5volt, 328 ohm maximum intrinsically safe barriers 64.

The high current ISB 62 is a 15 volt/5 ohm barrier certifiedintrinsically safe by the Canadian Standards Association (CSA) and byUnderwriters Laboratories (UL). Such a high current ISB is preferablyModel No. WE77-111/Ex manufactured by Peppral & Fuchs, Inc. located inTwinsburg, Ohio 44087-2202. Each high current ISB provides power to aseparate intrinsically safe peripheral. More specifically, one 15 volt/5ohm ISB 62 is included to power the intrinsically safe driller's monitor16. Up to a total of three intrinsically safe satellite boxes 18-20 canthen be separately powered by the three remaining high current ISBs 62.The high current ISB provides a means of delivering a relatively largeamount of power into an area that has been classified as hazardous, butprovides that power at safe levels.

The barrier box 14 also includes four conventional 25.5 volt/328 ohmintrinsically safe barriers 64 for supplying 24 volts DC power tosatellite boxes 18-20. Preferably, ISBs 64 are manufactured by ElconInstruments, Inc., Model No. MB4/2/18+/F2, These barriers 64 provide ameans for powering various other 4-20 milliamp sensors which require ahigher voltage than can be supplied with the high current barriers 62.

The driller's monitor 16 and each satellite box 18-20 are eachseparately connected to the barrier box 14 by a dedicated compositecable 41-44 (best shown in FIGS. 1 and 8) which includes both includingelectrical conductors and fiber optic conductors. More specifically,each composite cable 41-44 includes three 18-gauge copper electricalconductors and two fiber optic conductors. These cables also eachinclude a continuous electrical shield and a drain wire. A suitablecable for this application is manufactured by Storm Products Company,and assigned Part No. 060992-6. One fiber optic conductor in each cableis provided to transmit signals from the master CPU box 12 to theinterconnected peripheral. The second conductor is provided to transmita signal from the peripheral to the master CPU box 12.

Intrinsically safe barriers 62 and 64 are mounted in the enclosure on amounting rail 66. Four nonconductive divider plate supports 68 generallydivide the enclosure into five separate chambers 71-75. A fiber opticcable connector 69 is retained in each chamber 71-74 and is mounted to adivider plate support 68. Connectors 69 are used to interconnect thefiber optic conductors in composite cables 41-44 with correspondingconductors in identical composite cables 27-30 (FIGS. 1 and 8) whichinterconnect barrier box 14 and master CPU box 12.

The barrier box enclosure 60 generally has what is referred to as anintrinsically safe side 80 and a nonintrinsically safe side 82. Powerfrom the master CPU box 12 enters enclosure 60 of barrier box 14 on thenonintrinsically safe side 82. The composite cables 41-44 servicing theintrinsically safe driller's monitor 16 and satellite boxes 18-20 whichare located in the hazardous area connect with enclosure 60 of barrierbox 14 on the intrinsically safe side 80. A nickel plated, copper busbar 76 which is approximately 10×3 mm is supported in enclosure 60 byterminals 77, 78 adjacent the nonintrinsically safe side 82. The groundwire 95 from each ISB 62, 64 is connected to bus bar 76 as shown.

High current intrinsically safe barrier 62 is best understood withreference to FIG. 10. ISB 62 generally includes an enclosure 94 housinga pair of identical zener diodes 84, 85 rated at 13 volts±5%, 50 wattsDO-5 as supplied by Solid State, Inc., Part No. 1N3312B. ISB 62 furtherincludes a wirewound resistor, RCD 272F, 5 ohms±1%, 10 watts, Peppral &Fuchs Part No. P00583, and a fast acting fuse rated 500 milliamps assupplied by Belling Lee, Part No. HRC L754/PCB (also designated asPeppral & Fuchs Part No. P00582). These components are interconnected asshown in FIG. 10 with terminal blocks 91 and 92 and the free space inthe enclosure 94 is filled with a potting compound, preferably aselastomer type compound, such as that manufactured by Stycast, Inc.,Part No. FT2850. Terminal block 91 is positioned on the nonintrinsicallysafe side of ISB 62 that faces the nonintrinsically safe side 82 of box60, while terminal block 92 faces the intrinsically safe side 80. Asknown to those skilled in the art, when connected as shown in FIG. 10,this intrinsically safe barrier 62 will operate to clamp the voltageavailable to the circuits connected to the intrinsically safe side ofthe barrier to 13 volts±5%. In normal operating conditions, withvoltages below the breakdown voltage of the zener diodes 84, 85, thediodes appear as an open circuit and thus do not conduct current. Shouldthe voltage supplied to the ISB 62 from master CPU box 12 exceed thebreakdown voltage of these zener diodes, the diodes quickly become ashort circuit to conduct the current to ground for all voltages abovethe breakdown point, thereby maintaining the voltage on theintrinsically safe side of the barrier to the permitted voltage levels.While one diode 84 would be sufficient for this function, to provideredundancy and thus greater reliability, a second zener diode 84 issupplied. It is preferred that ISB 62 also include provisions formounting a third and even a fourth such zener diode in parallel withdiodes 84 and 85 for even greater safely assurances.

Referring again to FIGS. 1 and 8, composite cable 44 interconnectsintrinsically safe barrier 62a with driller's monitor 16. Cables 41through 43 interconnect intrinsically safe barriers 62b and 64b withtheir respective intrinsically safe satellite boxes 18-20. Cable 45,which may include only electrical conductors, interconnectsintrinsically safe barrier 64e with intrinsically safe horn 22. On thenonintrinsically safe side of barrier box 14, cable 27 interconnectsintrinsically safe barrier 62a with master CPU box 12. Similarly,composite cables 28-30 interconnect their respective intrinsically safebarriers 62, 64 with master CPU box 12. Cables 28-30 are all compositecables comprising a pair of fiber optic conductors and three electricalconductors, a shield and drain wire. Cable 27, which supplies only 12volts DC to driller's monitor 16, may be identical to cables 28-30, butonly requires a pair of electrical conductors.

DRILLER'S MONITOR

The driller's monitor 16 includes an IBM XT class computer modified soas to have exceptionally low power requirements. The driller's monitor16 includes a large format LCD screen, 640×400 resolution, and amembrane type keypad. The driller's monitor also includes a monitorinterface board which includes an onboard microcontroller, and powerconditioning devices and circuitry to meet the intrinsically safecertification requirements. Driller's monitor 16 has a Temperature CodeT3C for Class 1, Division I, Groups C and D hazardous locations as setout in Table 2 in CSA standard C22.2 No. 157-M1987. Because of itsintrinsically safe certification, including the requisite spark ignitionand thermal ignition testing set out in C22.2 No. 157-M1987, neither themonitor nor its components are capable of igniting a Group C or D gas innormal use, or under any conditions of fault likely to occur inpractice. At an ambient temperature of 40° C., the maximum surfacetemperature of components in monitor 16 under fault conditions is 160°C. The monitor interface board further includes communication circuitryallowing the driller's monitor 16 to communicate with the master CPU box12 via fiber optic cable. As previously mentioned, the fiber optic cableprovides for electrical isolation and eliminates the need for severalconductors as are normally required for electrical communications. Thefiber optic conductors are also totally immune to electrical noise whichis prevalent in the hostile environment in which the equipment operates.Because of the low power requirements of the driller's monitor 16, itneed not be purged nor is it required to be housed in an explosion proofenclosure.

Intrinsically safe driller's monitor 16 is shown in FIGS. 11-16 andvarious components of monitor 16 are described in detail in Table 16.Referring first to FIGS. 11-13, driller's monitor 16 generally includesa hooded enclosure 110 housing CPU board 112, liquid crystal display(LCD) 114, and LCD driver board 116, monitor interface board 118, andmembrane keypad 120. The arrangement of these components withinenclosure 110 is best shown in FIGS. 13 and 14.

As with the satellite PCB 52 in satellite boxes 18-20, describedpreviously, all of the printed circuit boards and components located inthe intrinsically safe driller's monitor 16 are strategically placed soas to avoid using components that individually could ignite thehazardous vapors, whether by spark or high temperature, during bothnormal and fault conditions. Also, to meet the CSA intrinsically safecertification, non-surface mount components were used throughout thePCBs on which there was any field wiring in driller's monitor 16 andsatellite boxes 18-20. Additionally, capacitors are spaced apart on theboard to likewise prevent such occurrences. Accordingly, it is importantto the present invention to ensure that in intrinsically safe monitor 16and satellite boxes 18-20 no capacitor has a capacity greater than 10microfarads and that no inductor has an inductance greater than 0.88milihenrys. Likewise, all conducting components on PCB's having anyfield wiring connections are maintained at a minimum distance apart,such minimum distance being approximately 6.33 millimeters. No componentwithin the driller's box 16 or satellite boxes 18-20 will operate, evenin a faulted condition at a temperature exceeding 160° C.

Enclosure 110 is supported on bracket 109 and knobs 108. A hood 107 ismovably attached to enclosure 110 by knobs 106. Enclosure 110 is again ablown fiberglass, shielded box that is approximately 14 inches wide, 12inches high and 6 to 7 inches deep. As shown in FIG. 13, enclosure 110includes a hinged cover 104. The hinged cover is fastened to the body ofenclosure 110 by six threaded fasteners 103. Membrane keypad 120 isadhesively attached to a 1/16 inch thick plate which is secured to thefront cover 104 below lens 122 by eight welded studs and nuts and aclosed cell neoprene gasket. Lens 122 is a 1/8 inch acrylic sheetmanufactured by ICI Acrylics and is held in place with sealing typescrews and sealed within cover 104 with General Electric RTV SiliconeNo. 102 sealant. Lens 122 allows visual observation ofinternally-mounted LCD 114.

CPU board 112 is preferably a CPU provided by Real Time Devices,Manufacturer's Part No. SG001-CMF8680. The CPU board 112 is generallyshown in FIG. 17. As shown, EEPROM 124 is disposed at one edge of board112. For use in intrinsically safe driller's monitor 16 of the presentapplication, the board 112 as supplied by Real Time Devices was modifiedas follows. First, referring to FIG. 17, pin 10 on P11 was clipped offflush with the plastic holder, P11 shown generally by reference number126. Pin 4 on P4 was likewise clipped off flush with its plastic holder,P4 generally represented by reference number 128. The ROM supplied byReal Time Devices was removed and replaced with an EPROM programmed tohave the desired instructions for the particular application of DAS 10.A jumper was removed from P14, designated by reference numeral 130.Additionally, wirewrapped jumpers are added to pins A and D of connector129. Pins B, C and E of connector 129 are not provided with suchjumpers.

Referring again to FIGS. 11 and 13, LCD 114 is preferably a 640×400 hightemperature 0.33 dot pitch LCD supplied by Optrex, Inc., Optrex Part No.DMF666AN-10. The maximum operating temperature of the LCD display is+50° C. It has a maximum supply voltage rating (logic) of 7 volts and amaximum supply voltage (LDC drive) of 30 volts (VCC-VSS) or 28 volts(VCC-VDAJ). The maximum input voltage is VCC+0.3.

The LCD driver board 116 is preferably a PCB manufactured by AmproComputers, Inc., Manufacturer's Part No. MMX-LCD-Q-02. The LCD driverboard 116 is a compact, low power, multimode LCD display controllermodule utilizing low power CMOS logic and requiring less than 0.5 wattof power. The LCD driver board 116 is best shown in FIG. 18.

Board 116, as supplied by the manufacturer, was specially modified forthe present application. Specifically, four RAMs U2-U5 designated by thereference numeral 136 in FIG. 18 were removed from the board andreplaced with RAM integrated circuits, 64K×4 bit DIP which consumedlower power, such replacement chips being supplied by manufacturer IntelCorporation, Part No. P21464-10. Additionally, integrated circuit U8supplied by Ampro and designated in FIG. 18 by reference numeral 138 wasremoved from driver board 116 and replaced with a 20 pin IC socket andan 8-bit magnitude comparator, supplied by National SemiconductorCorporation, and designated by the manufacturer's Part No. MM74HCT688.Additionally, a wirewrapped jumper was added between pins 1 and 2 onW1-W5, W1-W5 are shown in FIG. 18 by reference number 141-145,respectively. A header J4, shown by reference numeral 147, was removedfrom board 116 and pin 19 on J3 was clipped flush with the plasticholder, J3 being identified by reference numeral 148.

The layout of components on the monitor interface board 118 is bestshown in FIG. 15, and the circuit diagram of the board is shown in FIG.16. Table 16 specifically identifies the components employed in monitorinterface board 118.

                                      TABLE 16                                    __________________________________________________________________________                                                              MATL                DESIGNATOR     QTY                                                                              NO.                                                                              PART NO.                                                                            DESCRIPTION                    REQD                __________________________________________________________________________                   1  49 LSS00017                                                                            BAG STATIC SHIELDING 8 × 12                                             FOAM/MACKPAC                   1                                  1  48 65-02-017                                                                           CNECTR 2 PIN FEM 12 AWG 5 MM                                                                                 1PACING             P1             1  47 65-02-015                                                                           CNECTR 2 PIN HEADER PCB MNT VERT                                                                             1HROUDED            CR1,CR2        2  46 74-17-170                                                                           DIODE 1N5341A ZENER 6.2 V 5W                                                                                 2/- 10%             R23,R20        2  45 72-06-121                                                                           RESIST 100 K  1/4W 5% C4 CORNING                                                                             2L0S104S            X1             1  44 80-06-573                                                                           CRYSTAL 4 MHZ HC-33/U          1                   L1             1  43 80-51-169                                                                           INDUCTOR 1.2 MHENRY AXIAL LEAD 1                   U6             1  42 72-03-285                                                                           RESIST, 3.3K OHM NETWORK DIP   1                   R6,R14,R16     3  41 72-06-042                                                                           RESIST  1/4W 51 OHM 5%         3                   R9,R21,R22     3  40 YRA14472                                                                            RESIST  1/4W 4700 OHM 5%       3                   R5             1  39 YRA14331                                                                            RESIST  1/4W 330 OHM 5%        1                   R4             1  38 YRA14302                                                                            RESIST  1/4W 3000 OHM 5%       1                                  1  37 YMP00076                                                                            SOCKET IC 20 PIN               1                                  1  36 YMP00052                                                                            SOCKET IC 40 PIN TIN LEADS     1                                  2  35 YMP00011                                                                            SOCKET IC 16 PIN               2                                  2  34 YMP00020                                                                            TERMNL UNINS TEST              2                   P7             1  33 YKM39020                                                                            CNECTR MALE HEADER 2-PIN 1 IN. PIN SPACE                                                                     1/LOC               C10,C11        2  32 YCM74706                                                                            CAPCTR 47PF MICA 44F6991       2                   C1             1  31 YCB22200                                                                            CAPCTR 22 MFD 25 V             1                   C3,C7,C8       3  30 61-50-007                                                                           CAPCTR 100 V .1 MFD KEMET C330C104MIVICA                                                                     3                   C9             1  29 YCA30100                                                                            CAPCTR 1 MD 35 V TANT 47F404   1                   P4             1  28 96-27-050                                                                           CABLE ASSY LCD DRIVE PCB INTERFACE SMART                                      SYSTEM                         1                   P2             1  27 96-27-049                                                                           CABLE ASSY KEYPOARD/PWR PCB INTERFACE SMART                                   SYSTEM                         1                   P3             1  26 96-27-048                                                                           CABLE ASSY COMMUNICATION SERIAL PCB INTRFC                                    SMART SYSTEM                   1                   P5             1  25 96-27-046                                                                           CABLE ASSY LCD PANEL PCB INERFACE SMART                                                                      1YSTEM              O1             1  24 74-80-795                                                                           XSISTR MJE172 POWER 3 AMP      1                   O2             1  23 74-78-833                                                                           XSISTR 2N3904 MOTOROLA         1                   D1             1  22 74-60-410                                                                           RECTFR MUR410 POWER 4 AMP 100                                                                                1                   D2-D5          4  21 74-09-363                                                                           DIODE IN914                    4                   R2             1  20 73-74-164                                                                           POT TRIMMER 100K  3/4W 20 TURN PCB MNT HORZ                                   ADJ                            1                   R3             1  19 73-74-080                                                                           POT TRIMMER 50K  1/2W 1 TURN PCB MNT VERT                                                                    1DJ                 R8             1  18 72-12-392                                                                           RESIST 1 W .2 OHMS 5% WIREBOUND                                                                              1                   R1             1  17 72-12-280                                                                           RESIST 1W 2000 OHM 5% CARBON   1                   R7             1  16 72-06-603                                                                           RESIST  1/4W 24000 OHM 5% CARBON                                                                             1                   R24,R25        2  15 72-06-582                                                                           RFSIST  1/4W 3300 OHM 5% CARBON                                                                              2                   R19,R17,R18    3  14 72-06-177                                                                           RESIST  1/4W 22K OHM 5% CORN                                                                                 3-4                 R11            1  13 72-06-169                                                                           RESIST  1/4W 10 MEG 5% FC      1                   R12            1  12 72-06-097                                                                           RESIST  1/4W 10K OHM 5% C-4    1                   R13,R15        2  11 72-06-081                                                                           RESIST  1/4W 2.2K OHM 5% C-4   2                   PW1            1  10 70-74-065                                                                           POWER SUPPLY 7-40 VDC IN/5 VDC OUT 3K MA PCB                                  MNT LO PR                      1                   U3             1  9  70-65-065                                                                           TRANSMITTER FIBER OPTIC HORIZ PLASTIC 40K BD                                  PCB                            1                   U4             1  8  70-60-065                                                                           RECEIVER FIBER OPTIC HORIZ PLASTIC 40K BD                                                                    1CB                 U5             1  7  67-95-880                                                                           IC ENCODER KEYBOARD            1                   U2             1  6  67-95-513                                                                           IC RS232 LINE DRIVER/RECEIVER  1                   U1             1  5  67-20-069                                                                           IC 78S40 UNIVERSAL SWITCHING                                                                                 1EGULATOR           P6             1  4  65-10-056                                                                           CNECTR 10 PIN HEADER PCB MNT RA POLARIZED .1                                  CEN                            1                   C4             1  3  61-55-523                                                                           CAPCTR 680 PFD 200 V CERAMIC                                                                                 1ONOLITHIC          C5,C6          2  2  61-55-505                                                                           CAPCTR 22 PFD 200 V CERAMIC MONOLITHIC                                                                       2                                  1  1  96-52-135                                                                           PCB BLANK MONITOR INTERFACE BOARD                                                                            1                   __________________________________________________________________________

Referring now to FIG. 16 and Table 16, serial connector P3 interconnectsmonitor interface board 118 with CPU board 112. Integrated circuitpackage U2 is an RS232 line driver/receiver identical to that previouslydescribed with reference to FIGS. 5, 6 and 7 in the intrinsically safesatellite box 18. U2, in conjunction with transistor Q2 and fiber optictransmitters and receivers U3 and U4, also previously described withreference to FIGS. 5, 6 and 7, provide a means for communicating betweendriller's monitor 16 and master CPU box 12 via fiber optic conductorsand composite cable 44 (FIG. 1). Power is received from the master CPUbox 12 via barrier box 14 at connector P1, the power more specificallybeing supplied through high current intrinsically safe barrier 62 shownin FIG. 8. The incoming power is controlled by a wide range DC to DCpower supply PW1. PW1 is a 7 to 70 VDC in/5 VDC out supplied by ComputerProducts, Inc., Part No. LWM12S05/3000XA. The outcoming 5 volt DC isthen distributed throughout the monitor interface board 118. Zenerdiodes CR1, CR2 are rated 6.2 volts 5 watts±10% and are provided toclamp the voltage to ensure that no greater than a maximum voltage of6.2+10% appears anywhere on the monitor interface board 118.

Keyboard encoder U5 is provided to transmit signals entered on membranekeypad 120 to master CPU box 12. U5 is an IC microcontroller provided byUsar Systems, Inc., designated by Usar as Part No. K25C 81P-SWA.Microcontroller U5 generates a signal transmitted to the keyboardinterface on the CPU board 112 via connector P2. Referring now to FIGS.15 and 16, the membrane keyboard 120 interconnects with interface board118 via mylar ribbon connector 121. Connector P2 is interconnected withCPU board 112 via ribbon connector 152. Ribbon connector 153interconnects P3 or LCD driver board 116 with CPU board 112.

Referring again to FIG. 16, monitor interface board 118 further includesa universal switching regulator U1 and inductor L1 which cooperate toprovide excitation signals for the LCD 114, such signals beingtransmitted to LCD 114 through connector P5 and ribbon connector 154(FIG. 14). This circuitry refreshes the LCD display and preventsflickering which may occur during certain lighting situations. ConnectorP4 interconnects to video driver board 116 via ribbon connector 155,also shown in FIG. 14.

The driller's monitor 16 is also provided with a potentiometer assembly119, shown in FIGS. 11, 12 and 14, which is connected to the monitorinterface board 118 at connector P7 shown in FIG. 16. This potentiometerprovides a brightness control for the LCD display 114. Potentiometerassembly 119 extends through a penetration in enclosure 110 and issealed with a sealing type locking nut.

MASTER CPU BOX

Referring again to FIG. 1, the master CPU box 12 is the hub of the dataacquisition system 10. All communications with and power distribution tothe various monitors and satellite boxes are conducted through themaster CPU box 12. The CPU box 12 communicates with remote sensors viaserial links to acquire data indicating the status of variousparameters. It also sends to the monitors all of their displayinformation. The master CPU box 12 also drives circular recorders, suchas recorder 26. The master CPU box 12 generally functions as aclearinghouse to distribute information input from any of the monitorsto the rest of the systems. It provides storage for the driller'smonitor software, calibration values, and system configurationparameters. The master CPU box 12 is itself not intrinsically safe andthus is installed in a nonhazardous or unclassified location.

The master CPU box 12 generally includes and houses an uninterruptablepower supply (UPS) 11, a standard industrial slot-board IBM 386AT typePC 13, an interface PCB 161 and an 8-channel breakout PCB 163.

The UPS 11 provides conditioned, noninterruptable power for the entiredata acquisition system 10. As understood by those skilled in the art,the UPS 11 powers the system in the event of a disruption of theincoming power to the system. The UPS 11 accepts AC input over a 47 to63 Hz frequency range. Acceptable input voltage range is 95 to 132 voltsAC. The UPS provides the DAS 10 a minimum of 15 minutes of operationtime should the incoming AC power source be disrupted. The intrinsicallysafe driller's monitor 16, the barrier box 14, the intrinsically safesatellite boxes 18-20, all sensors 31-38, and the master CPU box 12itself, are all supplied by the UPS 11. A UPS suitable for the presentinvention includes Model No. AT300R as manufactured by Magnum PowerSolutions, ltd.

The slot-board PC 13 includes a passive backplane, 386DX-33 CPU board, aRAM/ROM board including EPROM's with software and nonvolatile memory forsystem calibration, alarm configuration and other data values. The PC 13further includes an 8-channel serial interface board and a 4-channel D/Aboard and an 8-channel relay board. Preferably the system will includeat least four MB of RAM. The 8-channel serial interface board in PC 13permits communication between the CPU box 12 and up to eight peripheraldevices which include monitors and satellite boxes. In addition to the8-channel serial interface board, the PC 13 itself includes two serialports such that the CPU box, in total, includes ten serial ports. Theinterface board allows standard RS232 serial, 4-wire current loop, andfiber optic communication with the peripherals. Should additionalchannels be required, the system is expandable by adding additionalboards.

The 4-channel D/A board in PC 13 generates voltage signals to drive upto four circular recorders. The 8-channel relay board in PC 13 permitsthe operation of an audible alarm such as a horn and a visual strobe,either or both of which may indicate alarm conditions. The remainingchannels may be used to switch either AC or DC voltage sources that maybe present in systems other than that shown in FIG. 1.

Power is distributed from the CPU box 12 via an interface PCB 161, bestunderstood with reference to FIG. 19 and Table 19.

                                      TABLE 19                                    __________________________________________________________________________                                                              MATL                DESIGNATOR     QTY                                                                              NO.                                                                              PART NO.                                                                            DESCRIPTION                    REQD                __________________________________________________________________________                   1  24 LSS00017                                                                            BAG STATIC SHIELDING 10 × 12 ANTI-STATIC                                FOAM                           1                                  4  23 YML00020                                                                            TERMNL UNINS TEST PT. .090     4                   C1,C3          2  22 YCA31002                                                                            CAPCTR .10 MFD 50 V DIP EPOXY  2                   C2,C4          2  21 YCA30100                                                                            CAPCTR 1 MFD 35 V TANT 47F404  2                   PTC1-PTC4      4  20 75-18-808                                                                           FUSE .45 AMP TRIP .30 AMP HOLD RESETABLE PCB                                  MNT                            4                   R12-R15        4  19 73-74-069                                                                           POT TRIMMER 10K  1/2W 25 TURN PCB MNT VERT                                                                   4DJ                 PWR2,PWR3      2  18 70-74-081                                                                           PWRSPY 5 VDC IN +/- 12 VDC OUT 2                   PWR1           1  17 70-74-073                                                                           PWRSPY 9-27 VDC IN/12 VDC OUT                                                                                1%                  P12            1  16 65-37-005                                                                           CNECTR 37 PIN D-SUB MALE PCB                                                                                 1NT                 P2             1  15 65-40-056                                                                           HEADER 40 PIN PCB MNT .1 SPAN  1                                  1  14 65-16-017                                                                           CNECTR 16 PIN FEM 12 AWG 5 MM SPACING                                         PLUGGABLE                      1                   P16            1  13 65-16-015                                                                           CNECTR 16 PIN HEADER PCB MNT VERT                                                                            1HROUDED                           1  12 65-15-017                                                                           CNECTR 15 PIN FEM 12 AWG 5 MM SPACING                                         PLUGGABLE                      1                   P15            1  11 65-15-015                                                                           CNECTR 15 PIN HEADER PCB MNT VERT                                                                            1HROUDED                           1  10 65-08-017                                                                           CNECTR 8 PIN FEM 12 AWG 5 MM SPACING                                                                         1LUGGABLE           P11            1  9  65-08-015                                                                           CNECTR 8 PIN HEADER PCB MNT VERT                                                                             1HROUDED                           1  8  65-90-506                                                                           TERMNL BLOCK PCB CONN 5 PIN    1                   P13            1  7  65-05-025                                                                           HEADER PCB VER 5 PIN           1                                  1  6  65-90-497                                                                           TERMNL BLOCK PCB CONNECTOR PLUGGABLE 4                                                                       1IN                 P14            1  5  65-04-015                                                                           CNECTR 4 PIN HEADER PCB MNT VERT                                                                             1PACING                            8  4  65-02-017                                                                           CNECTR 2 PIN FEM 12 AWG 5 MM SPACING                                                                         8LUGGABLE           P3-P10         8  3  65-02-015                                                                           CNECTR 2 PIN HEADER PCB MNT VERT                                                                             8HROUDED            P1             1  2  65-04-025                                                                           CNECTR 4 PIN HEADER PCB MNT VERT DETENT .2                                    CENT                           1                                  1  1  96-52-137                                                                           PCB BLANK J-BOX INTERFACE      1                   __________________________________________________________________________

The interface board 161 receives power at connector P1 from UPS 11. DCto DC power supplies PWR2, PWR3 supply +/-12 volts to generate a 24 voltsupply to power the 25.5 volt, 328 ohm ISBs 64 located in barrier box 14as shown in FIG. 8. The 15 volt, 5 ohm, high current ISBs 62, also shownin FIG. 8, receive a 12 volt supply from PCB 161 via connectors P3-P5.Driller's monitor 16 is supplied a 12 volt supply through at DC to DC+12 volt, 1% power supply PWR1 through connector P6. The 12 voltssupplied to driller's monitor 16 and satellite boxes 18-20 throughbarrier box 14 are controlled by PTC1-4 which are 0.45 amp tripresettable fuses made by Raychem Corporation, Part No. RXE030. If anovercurrent is experienced on a circuit supplying those peripherals, theresettable fuse opens, but will reclose once the fault condition hasbeen cured. PWR1 is inserted in the circuit servicing the driller'smonitor 16 so as to strictly regulate the 12 volts it receives to ±1%.

CPU interface board 161 further includes a connector P2 whichinterconnects board 161 with the D to A PCB in PC 13. Digital signalsreceived by the master CPU box 12 from the satellite boxes 18-20 areconverted to analog signals by the D to A converter. These signals arethen transmitted to interface board 161 at connector P2 and sent viaconnector P11 to circular recorder 26 (FIG. 1) or up to a total of foursuch circular recorders, strip charts or other such analog devices. Thepotentiometers R12 through R15 are supplied in order to scale the 0 to10 volt signal received from the D to A board in PC13 to a 0 to 5 voltscale, for example.

Referring still to FIG. 19, connector P12 is an input connectorinterconnecting an 8-channel relay board in PC 13 with interface board161. P13 includes a relay for activating horn 22 located in thehazardous area. Horn 22 is interconnected at P13 with cable 45, shown inFIG. 1. P15 includes seven additional relays for other desiredfunctions. For example, relay number 2 may be used to activate aflashing strobe or other visual indicator as may be required by certainregulatory agencies in the event that horn 22 is disabled. Connector P16is not used in DAS 10 described herein but may be used in conjunctionwith additional relays in systems where additional relays would bedesirable.

The 8-channel breakout PCB 163 is best understood with reference to FIG.20 and Table 20.

                                      TABLE 20                                    __________________________________________________________________________                                                              MATL                DESIGNATOR     QTY                                                                              NO.                                                                              PART NO.                                                                            DESCRIPTION                    REQD                __________________________________________________________________________                   1  16 LSS00017                                                                            BAG STATIC SHIELDING 8 × 12                                             FOAM/MACKPAC                   1                                  8  15 65-02-017                                                                           CNECTR 2 PIN FEM 12 AWG 55 MM SPACING                                         PLUGGABLE                      8                                  8  14 YKH99020                                                                            JUMPER BERG STICK 65474-001    8                                  3  13 YML00020                                                                            TERMNL UNINS TEST PT..090      3                   C2,C4          2  12 YCA30100                                                                            CAPCTR 1MFD 35 V TANT 47F704   2                   C1,C3          2  11 61-50-007                                                                           CAPSTR 100 V .1 MFD KEMET C330C104MICUICA                                                                    2                   R3,R6,R9,R12   8  10 72-06-011                                                                           RESIST  1/4W 2.7 OHM 5% LITTLE DEVIL                                                                         8MITE               R15,R18,R21,R24                                                               B1-B8          8  9  YKH99030                                                                            BERG STICK 3 POSITION          8                   LD2,LD4,LD6,LD8                                                                              8  8  68-15-013                                                                           LED RED RECT                   8                   LD10,LD12,LD14,LD16                                                           LD1,LD3,LD5,LD7,LD9                                                                          8  7  68-15-010                                                                           LED GREEN RECT                 8                   LD11,LD13,LD15                                                                R1,R2,R4,R5,R7,R8,R10,R11,R13,                                                               16 6  72-06-059                                                                           RESIST  1/4W 270 OHM 5% CORNING                                                                              16                  R14,R16,R17,R19,R20,R22,R23                                                   P2,P4,P6,P8,P10,P12,P14,P16                                                                  8  5  65-02-015                                                                           CNECT 2 PIN HEADER PCB MNT VERT                                                                              8HROUDED            P1,P3,P5,P7,P9,P11,P13,P15                                                                   8  4  65-25-010                                                                           CNCTR 25 PIIN D-SUB MALE PCB                                                                                 8NT                 P17            1  3  65-04-025                                                                           CNECTR 4 PIN HEADER PCB MNT VERT DETENT .2                                    CENT                           1                   P18            1  2  65-48-101                                                                           CNECTR 48 PIN HEADER PCB MNT RA MODULAR 8                                                                    1OS                                1  1  96-52-125                                                                           PCB BLANK 8 CHANNEL BREAKOUT   1                   __________________________________________________________________________

Power to the board 163 is supplied in the same manner as shown in FIG.19 with respect to interface board 161. Board 163 includes eightdiscrete circuits, each of which is identical to the one shown in FIG.20. The input to each of these circuits is made at connector P18. Aseparate input is supplied to each of the eight circuits from the eightdiscrete channels on the 8-channel serial board in the slot board PC 13.A communication module, identical to that previously shown and describedwith respect to FIGS. 6 and 7, is inserted into P7 which is a 25 pinmale connector. The communication module thus provides a means forreceiving fiber optically transmitted signals from the intrinsicallysafe driller's monitor 16 and satellite boxes 18-20, converting thosesignals to electrical signals and transmitting them to the CPU board inPC13. Likewise, the module converts signals from the CPU in PC 13 intolight pulses for transmitting to driller's monitor 16 and satelliteboxes 18-20. Each circuit is supplied with a means for monitoringtransmissions both to and from the CPU in PC13 by means of LEDs,specifically LD7 and LD8. These LEDs are again troubleshooting deviceswhich allow for quick visual detection of whether communications arebeing transmitted between the various peripheral devices and the CPU.Power is supplied to the communication module inserted into connector P7through pin 25. The 5 volts is supplied to pin 10 on P7 to drive LEDsLD7 and LD8.

SUMMARY

The above-described data acquisition system 10 offers many significantadvantages over the prior art. First, expensive and bulky explosionproof or purged enclosures are not required for housing the driller'smonitor. Further, no installation of purge air piping is required.

Further, because only a single composite cable 41-43 is needed tointerconnect a satellite box 18-20 with barrier box 14, as opposed toprior art methods (which would require that a multiconductor cable beused which would include at least one pair of wires for each sensor),the cabling cost and interconnection time are drastically reduced whenemploying the present invention. The composite cable 41-43 has a smalldiameter, is light weight and easily installed and is relativelyinexpensive. In prior art methods where multiple wire pairs wererequired to be run long distances from the junction box in the hazardousarea back to the barrier box, a large diameter, heavy and bulkymulticonductor cable was used. Such cables can be very difficult toinstall and are relatively expensive.

Additionally, it should be noted that to monitor ten channels in abarrier box using the present invention, only a single high current ISB62 is required (although the 24 volt/328 ohm ISB 64 is included foradded flexibility in the type of sensors which can be monitored). Thus,considering two ISBs per satellite box, only a fifth of the barriersconventionally required are utilized in the present invention. Thisoffers significant cost savings.

An additional important advantage is provided by the satellite box 18including a power conditioning circuit to remove electricalcontamination before power is supplied to each sensor. Additionally, thepresent invention eliminates a previously existing problem of electricalnoise being induced into the multiconductor cable connecting thejunction box within the hazardous barrier to the barrier box in anonhazardous area. Using the present invention, the microcontroller U5on the satellite PCB 52 performs the required analog to digitalconversion, provides the rate calculations and accumulation of eventpulses, and transmits that data stream from the hazardous area to thebarrier box in the intrinsically safe area via the fiber opticconductors, Thus, the present invention eliminates the opportunity forelectrical noise to be induced in the communication meansinterconnecting the barrier box and the satellite box. An addedadvantage of performing the various analog to digital conversions andcalculations within the satellite box is that the other systemcomponents, especially the master CPU box 12, operate more efficientlyby removing a significant number of calculations from its requiredfunctions.

What is claimed is:
 1. A data acquisition system for use in a regionthat includes a hazardous area, said system comprising:a master CPU boxlocated outside the hazardous area for distributing power throughoutsaid system; a plurality of intrinsically safe sensing devices locatedwithin the hazardous area for sensing predetermined parameters; anintrinsically safe satellite box located within the hazardous area fortransmitting power to said sensing devices and for collecting datasensed by said sensing devices, said satellite box including:an onboardCPU; and a means for transmitting data collected from said sensingdevices and processed by said onboard CPU to said master CPU box on asingle channel; an intrinsically safe console located within thehazardous area for communicating with said master CPU box, said consoleincluding:a monitor for displaying data received from said master CPUbox; an internal CPU; anda data entry device; and a barrier box locatedoutside the hazardous area for receiving power from the master CPU boxand redistributing the power to said satellite box and saidintrinsically safe console.
 2. The data acquisition system according toclaim 1, further including a plurality of intrinsically safe satelliteboxes, wherein said barrier box includes a separate intrinsically safebarrier for said intrinsically safe console and for each of saidintrinsically safe satellite boxes, for ensuring that the powerdistributed to said intrinsically safe console and said intrinsicallysafe satellite boxes is at a current level and voltage level that willnot ignite substances in the hazardous area and wherein eachintrinsically safe satellite box receives power from a singleintrinsically safe barrier.
 3. The data acquisition system according toclaim 2 wherein said intrinsically safe barriers each comprise a highcurrent, 15 volt, 5 ohm intrinsically safe barrier.
 4. The dataacquisition system according to claim 3 wherein said barrier box furtherincludes a plurality of 25.5 volt/328 ohm intrinsically safe barriersfor supplying 24 volts DC power to said satellite boxes.
 5. The dataacquisition system according to claim 4 wherein each of said satelliteboxes is supplied with power from a separate intrinsically safe barrier.6. The data acquisition system according to claim 3 wherein each of saidhigh current intrinsically safe barriers includes an enclosure housing azener diode rated at 13 volts±5%, 50 watts DO-5.
 7. The data acquisitionsystem according to claim 6 wherein each of said high currentintrinsically safe barriers further includes a wirewound resistor rated5 ohms±1%, 10 watts, and a fast acting fuse rated 500 milliamps.
 8. Thedata acquisition system according to claim 1 wherein communicationbetween each of said satellite boxes and said master CPU box throughsaid barrier box is via a single composite cable comprising at least twoelectrical conductors and at least one fiber optic conductor.
 9. Thedata acquisition system according to claim 8 wherein said satellitebox's onboard CPU converts said sensed data into a digital data streamand, upon being polled by said master CPU box, transmits a digital datastream serially from the hazardous area to said master CPU box via saidbarrier box and said fiber optic conductors in said composite cables.10. The data acquisition system according to claim 1 wherein each ofsaid satellite boxes further includes a data acquisition board, saidboard comprising components selected such that none are capable ofigniting vapors that may be present in the hazardous area, either byvirtue of either temperature or sparking under either normal or faultconditions.
 11. The data acquisition system according to claim 10wherein said components on said board are provided with separate voltageregulators.
 12. The data acquisition system according to claim 11wherein said components on said board include a microcontroller havingan internal analog to digital converter.
 13. The data acquisition systemaccording to claim 12, further including an RS232 line driver/receiverfor enabling communications between said microconttroller and saidmastter CPU box.
 14. The data acquisition system according to claim 1wherein said monitor further includes a CPU board, a liquid crystaldisplay, an LCD driver board, and a monitor interface board, saidmonitor interface board including an onboard microcontroller and powerconditioning devices to meet intrinsically safe certificationrequirements.
 15. The data acquisition system according to claim 14wherein said LCD driver board is a compact, low power, multimode LCDdisplay controller module utilizing low power CMOS logic and requiringless than 0.5 watt of power.
 16. The data acquisition system accordingto claim 15 wherein the maximum surface temperature of components insaid monitor under fault conditions is 160° C. at an ambient temperatureof 40° C.
 17. The data acquisition system according to claim 1 whereinsaid master CPU box includes an uninterruptable power supply, a standardindustrial slot-board, an interface and an 8-channel breakout.
 18. Thedata acquisition system according to claim 1, further comprising atroubleshooting circuit enabling an operator to select various optionsand obtain a visual indication of data transmission into or away fromsaid satellite boxes.
 19. The data acquisition system according to claim1 wherein said sensing devices include sensors generating analogsignals, and wherein all conversion of analog signals to digital signalsis performed in said satellite box.
 20. The data acquisition systemaccording to claim 1 wherein a single high current ISB in said barrierbox supplies power to all of said intrinsically safe sensing devices.21. The data acquisition system according to claim 1 wherein said dataacquisition system includes a plurality of intrinsically safe satelliteboxes, and wherein said barrier box includes a dedicated high currentISB for each of said satellite boxes, and wherein each dedicated highcurrent ISB supplies power to all the intrinsically safe sensing devicesthat receive power from the satellite box to which said ISB isdedicated.